Wire rope classifications and features
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When it comes to
showing you the ropes, no one does it like HUNAN HM MACHINERY. Our products are
backed by years of experience in the field, at your side – solving tough
problems in unique applications. We’ve matched the science of design with the
art of skillful manufacturing craftsmanship to build the best wire rope in the
world. No matter where you are in the world, Our manufacturing standards
typically exceed the minimum design standards for a wire rope. We take an
active role in industry associations that develop wire rope specifications and
standards, Wire rope basics Learn the basics of wire rope, including the
nomenclature, how it is constructed, and how diameter and lay measurements are
made. Proper rope use Learn how to choose the right ropes for your needs, how
to extend rope service life, the importance of inspection, and how to properly store
and handle wire rope.
Number of strands
and construction determine wire rope classification
Wires are the
basic building blocks of a wire rope. They lay around a “center” in a specified
pattern in one or more layers to form a strand. The strands are helically laid
together around a center, typically some type of core, to form a wire rope.
Wire rope classifications and features The strands provide all the tensile
strength of a fiber core rope and over 90% of the strength of a typical
6-strand wire rope with an independent wire rope core. Properties like fatigue
resistance and resistance to abrasion are directly affected by the design of
strands. In most strands with two or more layers of wires, inner layers support
outer layers in such a manner that all wires may slide and adjust freely when
the rope bends. As a general rule, a rope that has strands made up of a few
large wires will be more abrasion resistant and less fatigue resistant than a
rope of the same size made up of strands with many smaller wires. The basic
strand constructions are illustrated at right.
Single layer
The most common
example of the single layer construction is a 7 wire strand. It has a single-wire
center with six wires of the same diameter around it.
Seale
This construction
has two layers of wires around a center with the same number of wires in each
layer. All wires in each layer are the same diameter. The strand is designed so
that the large outer wires rest in the valleys between the smaller inner wires.
Example: 19 Seale (1-9-9) strand.
Filler wire
This construction
has two layers of uniform-size wire around a center with the inner layer having
half the number of wires as the outer layer. Small filler wires, equal in
number to the inner layer, are laid in valleys of the inner layer. Example: 25
Filler Wire (1-6-6f-12) strand.
Warrington
This construction
has two layers of wires around a center with one diameter of wire in the inner
layer, and two diameters of wire alternating large and small in the outer
layer. The larger outerlayer wires rest in the valleys, and the smaller ones on
the crowns, of the inner layer. Example: 19 Warrington [1-6-(6+6)].
Combined patterns
When a strand is
formed in a single operation using two or more of the above constructions, it
is referred to as a “combined pattern.” This example is a Seale construction in
its first two layers. The third layer utilizes the Warrington construction, and
the outer layer is a Seale construction. It’s described as: 49 Seale Warrington
Seale [1-8-8-(8+8)-16].
Standard rope
classifications
All rope of the
same size, grade and core in each classification have the same minimum breaking
force and weight per foot. Different constructions within each classification
differ in working properties. Consider these features whenever you’re selecting
a rope for a specific application.
Special rope
constructions
Unusual operating
conditions often require ropes of special ropes to better withstand stresses or
environments that would seriously impair performance of standard ropes. Ropes
that may meet these needs include the following:
> Flex-X® A special process that creates more strand
surface area on the rope to help spread contact, decrease wear, reduce drum and
sheave wear and extend service life. With greater surface area and more steel
per diameter than conventional ropes, Flex-X provides higher strength and
better wear resistance. Its high-density strands are compacted for extra
strength and resistance to abrasion, crushing and bending fatigue.
TUF-KOTE®/PFV® A
plastic impregnated wire rope proven to provide longer service life and a
cleaner operation. On the inside, top-of-the-line wire rope resists the
demanding pressures of your job. The polymer is applied at high pressure to
force the material into the rope, serving to cushion the strands, distribute
internal stresses, keep in wire rope lubricant and keep out dirt and debris. On
the outside, the engineered polymer plastic is designed to provide a cleaner
operation and reduces wear on sheaves and drums.
> 7-Flex® A wire rope that offers improved
resistance to bending fatigue when compared to standard 6x19S and 6x26WS
constructions of the same diameter due to a combination of the outer wire size
and the seventh strand. Its strand constructions provide a good combination of
overall operating properties.
> Flex-X® 7 CC
Already a preferred rope for container cranes, Flex-X 7 CC is now providing
extended service life in carriage operations and other applications where
multi-sheave equipment and rigorous duty cycles induce fatigue stresses.
> TUF-MAX®
These shovel ropes are manufactured with an enhanced coating process that makes
them more resistant to external rope wear and helps extend drum and sheave
life.
> PowerMax® An
8-strand wire rope created to provide operating properties essential to drag
and hoist ropes. PowerMax is more fatigue resistant than 6-strand ropes of the
same diameter, plus, its greater surface area puts more steel in touch with
contact surfaces reducing wear and abrasion.
> Flattened
(triangular) strand These ropes feature “shaped” strands formed so they will
close together to achieve greater metallic area in the rope’s crosssection and
greater bearing surface for contact with sheaves and drums.
> Swaged ropes
These ropes offer higher strength than standard ropes of the same diameter
while providing greater resistance to drum crushing, scrubbing and similar
surface wear. During manufacturing, the rope is swaged to produce a compact
cross-section with minimum voids and greater surface area.
Rope cores form a
foundation for the strands The primary function of the rope’s core is to serve
as the foundation for the strands – to keep the rope round and the strands
properly positioned during operation. Your choice of core will have an effect
upon the rope’s performance. Three types of cores are commonly used: 1. Fiber
core Polypropylene is standard, but either natural sisal (or hemp) fiber or
other man-made fibers are available on special request. 2. Independent Wire
Rope Core Literally an independent wire rope with strands and a core, called
IWRC. Most wire ropes made with steel core use an IWRC. 3. Strand core A strand
made of wires. Typically, strand cores are used in utility cables only.
Three types of
rope cores:
> Fiber Core
> Independent Wire Rope Core > Strand Core
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